Method for fabricating automotive interior components

Abstract

A method for fabricating an automotive interior component. The automotive interior component consists of a laminated structure comprising a resin core member having a certain rigidity, a high density polyurethane foam layer, and a soft surface skin member. Since the high density polyurethane foam is bonded over the reverse surface of the surface skin member which is typically lined by a soft foam layer for giving a soft feel, it is possible to bond the surface skin member over the resin core member at the same time as mold press forming the resin core member from semi molten resin owing to the heat insulation and barrier capabilities of the high density polyurethane foam layer. Since the conduction of heat from the semi molten resin to the soft foam layer of the surface skin member is avoided, and the press pressure is mitigated so that the collapsing of the foam layer during the press molding process is prevented. The present invention further offers the advantage of simplifying the fabrication process by thus accomplishing the bonding of the surface skin member over the resin core member and the mold press forming of the resin core member at the same time as a single step.

What we claim is: 
     
       1. A method for fabricating an automotive interior component, comprising the steps of: positioning a surface skin member between a first mold part and a second mold part, said surface skin member having a PVC skin sheet facing the second mold part, a layer of high expansion ratio soft polyolefin foam adjacent the PVC skin sheet, and a layer of high density urethane foam having a density of 0.03 to 0.05 g/cm 3  and a thickness greater than 2 mm facing the first mold part and wherein said surface skin member has its peripheral part retained by a clamping device;   feeding a predetermined amount of a resin material in a semi-molten state onto a mold surface of the first mold part following said positioning step;   moving said mold parts together to initiate a mold press forming operation;   forming a resin core member into a desired shape by engaging the first and second mold parts for mold press forming with each other; and   integrally joining the resin core member with the surface skin member during said forming step;   wherein the layer of high density urethane foam prevents the collapse of the layer of high expansion ratio soft foam during said forming step.